Synthetic Roofing Shingle

ABSTRACT

A monolayer synthetic or artificial thatch shingle comprising a plurality of tapering extensions extending from a base flange member, the thatch shingle having been formed from a thin sheet of stiff plastic, and the extensions having been formed by removing material from the thin sheet. The base flange member presents a solid surface, such that when shingles are overlaid in successive rows advancing up the pitched roof, the combination of overlapping base flange members provides a water barrier such that all rain water is directed from the slanted roof.

This application claims the benefit of U.S. Provisional patent Application Ser. No. 61/760,794, filed Feb. 5, 2013.

BACKGROUND OF THE INVENTION

This invention relates general to synthetic or artificial roofing shingles or similar products used as the external covering on a roof, wherein the synthetic shingles are manufactured to resemble and present the appearance of a natural roof covering once installed.

Roof coverings composed of natural plant materials, such as reeds, grasses, palm leaves or the like, are well known in many parts of the world. Such roof coverings are often referred to generically as thatch roofing. A significant market for thatched roofing has developed, and in particular for synthetic or artificial thatched roofing, since the useful lifespan of the natural materials is relatively short when compared to the useful lifespan of synthetic thatch roof covering, which is made from one or more polymers, such as for example high density polyethylene (HDPE) or polyvinyl chloride (PVC). In addition, additives may be mixed with the polymers to improve resistance to degradation from UV light or to improve fire resistance. The thatch roof coverings are usually provided in shingle form and are formed by bending and folding a plurality of thin elongated members about or within a binder, such that the binder may then be attached to the roof. A waterproof underlayment is usually required, since this type of synthetic roofing shingle is not waterproof and primarily serves an aesthetic purpose. The known synthetic thatch shingles also suffer from problems not inherent in the synthetic grass or reed shingles because of the broader width of the individual elements. For example, in known synthetic thatch shingles, the finger-like extensions are susceptible being bent backwards and permanently crimped by strong winds.

It is an object of this invention to provide a synthetic thatch shingle, along with its method of manufacture, that improves on the known synthetic shingles, such that the synthetic thatch shingles create a water-proof barrier when installed and such that the extensions of the synthetic thatch shingles are resistant to wind damage. It is a further object to present such shingles which are simpler to manufacture and install.

SUMMARY OF THE INVENTION

The invention is a monolayer synthetic or artificial thatch shingle comprising a plurality of pointed or tapering extensions extending from a base flange member, the thatch shingle having been formed from a thin sheet of undulating stiff plastic. The extensions are preferably about 12 inches in length and preferably no greater than about ⅜ inches in width, with the extensions preferably varying in length, width and configuration to impart a natural look, and the base flange member is preferably about 8-9 inches in length, but may be greater or smaller. The width of the base flange member may vary. The base flange member presents a solid surface, such that when shingles are overlaid in successive rows advancing up the pitched roof, the combination of overlapping base flange members provides a water barrier such that all rain water is directed from the slanted roof. The undulations in the thin sheet may vary in configuration, but preferably are formed as a series of ridges elongated in the same direction as the extensions, with the ridges preferably being approximately ½ inch in width. In another embodiment, the base flange member is provided with wave undulations, each wave undulation encompassing a plurality of ridges.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a top view of an embodiment of the synthetic thatch shingle.

FIG. 2 is bottom view of the shingle of FIG. 1.

FIG. 3 is a perspective view of the shingle of FIG. 1.

FIG. 4 is an enlarged view of a portion of the shingle of FIG. 1 showing the convex ridges and the bases of the extensions.

FIG. 5 is an underside view showing an alternative embodiment of the synthetic thatch shingle having wave undulations.

DETAILED DESCRIPTION OF THE INVENTION

With reference to the drawings, the invention will now be described. The term “thatch” or “thatched” as used herein shall refer a roof covering or roofing material mimicking natural roof coverings such as palm leaves, grass, reeds, etc.

The synthetic or artificial thatch shingle 10 is a monolayer body comprising a plurality of pointed or tapering extensions 11 extending from a base flange member 12, the thatch shingle 10 comprising a thin sheet of stiff plastic, such as for example HDPE or PVC. The extensions 11 may be similar in configuration, but more preferably will vary in width, length and configuration to better represent the appearance of a natural palm leaves, grasses, reeds, etc. While dimensions are not critical, the extensions 11 are preferably about 12 inches in length, and preferably no greater than about ⅜ inches in width to reduce wind damage and allow the extensions 11 to retain their original shape after a wind event. The base flange member 12 is preferably about 8-9 inches in length, i.e., in the direction parallel to the elongated extensions 11, but may be greater or smaller. The base flange member 12 comprises a solid surface, such that when the shingles 10 are overlaid in successive rows advancing up the pitched roof, the combination of overlapping base flange members 12 provides a water barrier such that all rain water is directed from the slanted roof. Thus, the base flange members 12 are preferably at least 4 inches in length so that an inordinate number of rows of shingles 10 are not required to insure a waterproof barrier. The width (i.e., the direction transverse to the elongated extensions) of the base flange member 12 may vary, and could be multiple feet.

The non-planar segments in the thin sheet comprising the base flange member 12 and the extensions 11 may vary in configuration, but preferably are formed as a series of ridges 14 elongated in the same direction as the extensions, with the ridges 14 preferably being approximately ½ inch in width. Thus the ridges 14 are convex when viewed from the upper side of the shingle 10, as seen in FIGS. 1 and 4, and are concave when viewed from the underside of the shingle 10, as seen in FIG. 2. Most preferably the ridges 14 are not periodically spaced and the junctions 15 between the ridges 14 not linear. This structure insures that when a superior shingle 10 is positioned on an inferior shingle 10, the base flange members 12 will not mate, but instead gaps, spaces and channels are formed that extend toward the extensions 11. With this structure, any rain water blown under the base flange members 12 or otherwise seeping between the overlapping base flange members 12 will easily drain downward and eventually off the roof.

In an alternative embodiment of the synthetic thatch shingles 10, the base flange member 12 or both the base flange member 12 and the extensions 11 are configured with generally S-shaped wave undulations 13 having lesser periodicity than the ridges 14, such that each recurring wave undulation 13 will encompass a plurality of ridge 14, as shown in FIG. 5. The shingles 10 are preferably formed such that for all shingles 10 one side ends in an upward directed portion of the wave and the other side ends in a downward directed portion of the wave, such that the side with the downward directed wave can be overlapped laterally with the side with the upward directed wave of an adjacent shingle 10. The shingles 10 with this configuration allow for improved air flow, especially in installations that are open on the underside as seen in FIG. 5. 

1. A monolayer synthetic thatch shingle comprising a plurality of tapering extensions extending from a base flange member, the thatch shingle being a thin sheet of stiff plastic, the extensions having been formed by removing material from the thin sheet, wherein the upper surface of the thin sheet comprises a plurality of convex ridges. 